Installation Manual for ➤ Corrugated Steel Pipe ➤ Pipe Arches ➤ Structural Plate NATIONAL C ORRUGATED S TEEL P IPE A SSOCIATION INSTALLATION MANUAL — NCSPA The NCSPA Installation Manual is not a copyrighted publication. If excerpted or copied, credit to the source would be appreciated. * * * The information contained in this Installation Manual is the product of industry experience and practice. The methods used to install corrugated steel pipe can affect both its effectiveness and useful life. The situations described in this publication and the suggested techniques for installation are general sugges- tions and guidelines intended to alert installers to the need for careful review of on-site conditions. Each installation will require its own individual evaluation. The statements or descriptions provided herein are for general information only. The National Corrugated Steel Pipe Association assumes no responsibility for their use. * * * NATIONAL CORRUGATED STEEL PIPE ASSOCIATION 1255 Twenty-Third Street, NW, Suite 200 Washington, DC 20037-1174 Phone: 202/452-1700 • Fax: 202/833-3636 E-mail: [email protected] • Web: www.ncspa.org 08 InstallMan00 CSP Installation Manual 1 TABLE OF CONTENTS FOREWORD .............................................................................................. 3 BASIC PRINCIPLES FOR PROPER CONSTRUCTION AND INSTALLATION ............................................. 4 LOCATION ................................................................................................. 5 EXCAVATION............................................................................................. 5 Embankment Condition.................................................................. 5 Trench Condition............................................................................ 5 Trench Width and Shape ................................................................ 6 PREPARING FOUNDATIONS................................................................. 7 Handling Poor Foundations............................................................ 7 Uneven Foundations....................................................................... 8 Soft Foundations............................................................................. 9 Pockets of Unstable Soil ................................................................ 9 Swampy Foundations ................................................................... 10 Improved Foundations.................................................................. 10 Settlement Under High Fill Loads ............................................... 10 Rock Foundations......................................................................... 11 Arch Foundations ......................................................................... 11 ASSEMBLY............................................................................................... 12 Unloading and Handling .............................................................. 12 Connecting Bands ........................................................................ 12 Installing Connecting Bands ........................................................ 12 Typical Connecting Bands ........................................................... 14 Gaskets ......................................................................................... 16 Mastic ........................................................................................... 17 Asphalt Coated Pipe..................................................................... 17 Paved-Invert Pipe.......................................................................... 17 Full Lined Pipe............................................................................. 18 Polymer Coated Pipe.................................................................... 18 Pipe Arch ...................................................................................... 18 Field Coated Structural Plate Structures ...................................... 18 Structural Plate Structures............................................................ 18 Tools Required ............................................................................. 19 Erection ........................................................................................ 19 Long Span Structures ................................................................... 21 Lifting Assistance......................................................................... 21 End Treatment .............................................................................. 21 08 InstallMan00 Cut End......................................................................................... 22 National Corrugated Steel Pipe Association 2 ASSEMBLY (continued) Cut-Off Walls ............................................................................... 23 End Sections................................................................................. 24 Other End Finishes....................................................................... 24 Stream Diversion.......................................................................... 24 BACKFILLING ........................................................................................ 25 Backfill Material........................................................................... 25 Placing the Backfill ...................................................................... 25 Pipe Arches................................................................................... 30 Arches........................................................................................... 30 Large Diameter Structures ........................................................... 32 Proper Material Placement........................................................... 32 Even Placement of Backfill.......................................................... 33 Shape Control............................................................................... 33 Multiple Installations.................................................................... 34 Long Span Structures ................................................................... 35 Final Backfilling........................................................................... 35 COMPACTION EQUIPMENT ............................................................... 35 Hand Compaction......................................................................... 35 Mechanical Compactors............................................................... 36 Roller Compactors........................................................................ 36 Vibrating Compactors .................................................................. 36 Hydraulic Compaction ................................................................. 36 Structure Protection...................................................................... 36 Construction Loads ...................................................................... 37 Hydraulic Protection .................................................................... 38 SUMMARY ............................................................................................... 40 SUBDRAINAGE ....................................................................................... 41 Underdrain Pipe............................................................................ 41 Flow Line ..................................................................................... 41 Preparing the Foundation ............................................................ 41 Assembly of Underdrain Pipe ...................................................... 41 Proper Placement of Underdrain Pipe.......................................... 42 APPENDIX................................................................................................ 44 Culvert Grades and Outfall Treatment ......................................... 44 Length of Culverts........................................................................ 44 Skew Number ............................................................................... 47 CSP Installation Manual 3 FOREWORD This manual is intended for both the contractor and the engineer. It provides practical information for the installation of corrugated steel pipe as storm sewers or culverts. It also provides the necessary considerations for proper design to achieve long term performance of the culvert or storm sewer. Corrugated steel pipe with its high load carrying capacity, strong joints and exceptional beam strength is installed more easily than other types of con- duit. However, the correct installation procedures must be followed to insure full investment value in the structure. It is the intent of this manual to suggest ways and means of improving installation practices. It is not intended to be used as a direct specifica- tion, but rather as a practical field guide for the installation of corrugat- ed steel pipe, pipe arch and structural plate. Too much emphasis cannot be placed on the necessity of adequate compaction of backfill. Faulty compaction has led to more trouble with pipe installations, flexible and rigid, than all other factors combined! OSHA safety regulations and guidelines must be observed during all phases of construction including foundation preparation, excavation, pipe handling, assembly and backfilling. Additional information is available in the AISI Handbook of Steel Drainage and Highway Construction Products and ASTM Specifications A 798 and A 807. This manual uses